U.S. patent application number 13/773110 was filed with the patent office on 2013-08-29 for method and apparatus for manufacturing fiber-reinforced base material.
This patent application is currently assigned to MITSUBISHI HEAVY INDUSTRIES, LTD.. The applicant listed for this patent is MITSUBISHI HEAVY INDUSTRIES, LTD.. Invention is credited to Kouji ESAKI, Takao KUROIWA, Kentaro SHINDO.
Application Number | 20130221568 13/773110 |
Document ID | / |
Family ID | 49001975 |
Filed Date | 2013-08-29 |
United States Patent
Application |
20130221568 |
Kind Code |
A1 |
SHINDO; Kentaro ; et
al. |
August 29, 2013 |
METHOD AND APPARATUS FOR MANUFACTURING FIBER-REINFORCED BASE
MATERIAL
Abstract
It is intended to provide a method and an apparatus for
manufacturing a fiber-reinforced base material, which is capable of
manufacturing a fiber-reinforced base material of high quality
while preventing generation of defects such as wrinkles during
stacking of the base material sheet. The method for manufacturing
the fiber-reinforced base material formed by stacking a base
material sheet including a reinforcement fiber onto a mold having a
double-curved surface shape, includes steps of: supplying the base
material sheet onto the mold from a base material roll while
applying distribution varying in a width direction (X direction) to
a length of the base material sheet in a sheet-supplying direction
of the base material sheet (Y direction) in correspondence with the
double-curved surface shape of the mold; and applying pressure to
the base material sheet in contact with the mold.
Inventors: |
SHINDO; Kentaro; (Tokyo,
JP) ; KUROIWA; Takao; (Tokyo, JP) ; ESAKI;
Kouji; (Tokyo, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MITSUBISHI HEAVY INDUSTRIES, LTD.; |
|
|
US |
|
|
Assignee: |
MITSUBISHI HEAVY INDUSTRIES,
LTD.
Tokyo
JP
|
Family ID: |
49001975 |
Appl. No.: |
13/773110 |
Filed: |
February 21, 2013 |
Current U.S.
Class: |
264/258 ;
425/505 |
Current CPC
Class: |
B29L 2031/085 20130101;
Y02P 70/523 20151101; B29C 43/222 20130101; Y02P 70/50 20151101;
B29C 70/38 20130101; B29C 43/18 20130101; B29K 2105/06 20130101;
B29C 70/388 20130101; B29C 2043/466 20130101; B29C 43/24
20130101 |
Class at
Publication: |
264/258 ;
425/505 |
International
Class: |
B29C 43/18 20060101
B29C043/18 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 29, 2012 |
JP |
2012-042638 |
Claims
1. A method for manufacturing a fiber-reinforced base material
formed by stacking a base material sheet including a reinforcement
fiber onto a mold having a double-curved surface shape, the method
comprising steps of: supplying the base material sheet onto the
mold from a base material roll while applying distribution varying
in a width direction to a length of the base material sheet in a
sheet-supplying direction of the base material sheet in
correspondence with the double-curved surface shape of the mold;
and applying pressure to the base material sheet in contact with
the mold.
2. The method for manufacturing the fiber-reinforced base material,
according to claim 1, wherein the base material roll has a
circumferential length varying in the width direction so as to
apply the distribution to the length of the base material sheet in
the sheet-supplying direction, and wherein, while supplying the
base material sheet onto the mold from the base material roll, an
outer periphery of the base material roll is pressed against the
mold over the base material sheet so as to apply pressure to the
base material sheet in contact with the mold.
3. The method for manufacturing the fiber-reinforced base material,
according to claim 1, wherein the base material roll has a
circumferential length varying in the width direction so as to
apply the distribution to the length of the base material sheet in
the sheet-supplying direction, and wherein, after supplying the
base material sheet onto the mold from the base material roll, the
base material sheet is pressed against the mold using an auxiliary
roll so as to apply pressure to the base material sheet in contact
with the mold.
4. The method for manufacturing the fiber-reinforced base material,
according to claim 1, wherein a roll gap is formed between a convex
roll and a concave roll, the convex roll being a curved roll
curving in the width direction so that a diameter is greater in a
center than at both ends, the concave roll being arranged parallel
to the convex roll and being a curved roll curving in the width
direction so that a diameter is smaller in a center than at both
ends, wherein the base material sheet drawn from the base material
roll is passed through the roll gap so as to apply the distribution
to the length of the base material sheet in the sheet-supplying
direction, and wherein, after supplying the base material sheet
having passed through the roll gap onto the mold, the base material
sheet is pressed against the mold using an auxiliary roll so as to
apply pressure to the base material sheet in contact with the
mold.
5. The method for manufacturing the fiber-reinforced base material,
according to claim 4, wherein a sheet-bending angle formed around
the roll gap between the base material sheet after passing through
the roll gap and the base material sheet before passing through the
roll gap is changed so as to adjust the distribution applied to the
length of the base material sheet in the sheet-supplying
direction.
6. An apparatus for manufacturing a fiber-reinforced base material
formed by stacking a base material sheet including a reinforcement
fiber onto a mold having a double-curved surface shape, the
apparatus comprising: a sheet supply unit for supplying the base
material sheet onto the mold from a base material roll while
applying distribution varying in a width direction to a length of
the base material sheet in a sheet-supplying direction of the base
material sheet in correspondence with the double-curved surface
shape of the mold; and a sheet contact unit for applying pressure
to the base material sheet supplied onto the mold in contact with
the mold.
7. The apparatus for manufacturing the fiber-reinforced base
material, according to claim 6, wherein the sheet supply unit
comprises a base material roll whose circumferential length varies
in the width direction so as to apply the distribution varying in
the width direction to the length of the base material sheet in the
sheet supplying direction, the base material roll being rolled
along the mold to supply the base material sheet onto the mold, and
wherein the sheet contact unit presses the base material roll
against the mold when the base material roll is rolled so as to
apply pressure to the base material sheet in contact with the
mold.
8. The apparatus for manufacturing the fiber-reinforced base
material, according to claim 6, wherein the sheet supply unit
comprises a base material roll whose circumferential length varies
in the width direction so as to apply the distribution varying in
the width direction to the length of the base material sheet in the
sheet supplying direction, the base material roll being rolled
along the mold to supply the base material sheet onto the mold, and
wherein the sheet contact unit comprises an auxiliary roll for
pressing the base material sheet arranged on the mold against the
mold so as to apply pressure to the base material sheet in contact
with the mold.
9. The apparatus for manufacturing the fiber-reinforced base
material, according to claim 6, wherein the sheet supply unit
comprises a convex roll and a concave roll, the convex roll curving
in the width direction so that a diameter is greater in a center
than at both ends, the concave roll being arranged parallel to the
convex roll and curving in the width direction so that a diameter
is smaller in a center than at both ends, the convex roll and the
convex roll forming a roll gap therebetween where the base material
sheet drawn from the base material roll is passed through so as to
apply the distribution to the length of the base material sheet in
the sheet-supplying direction, and wherein the sheet contact unit
comprises an auxiliary roll for pressing base material sheet
against the mold so as to apply pressure to the base material sheet
in contact with the mold.
10. The apparatus for manufacturing the fiber-reinforced base
material, according to claim 9, further comprising: an angle
adjustor for adjusting a sheet-bending angle around the roll gap
between the base material sheet after passing through the roll gap
and the base material sheet before passing through the roll gap.
Description
TECHNICAL FIELD
[0001] The present invention relates to a method and an apparatus
for manufacturing a fiber-reinforced base material which is used as
a base material of resin composite including reinforcement
fiber.
BACKGROUND ART
[0002] Composites such as FRP (Fiber Reinforced Plastic) including
reinforcement fiber are lightweight and have high strength. Thus,
the composites are increasingly used for components of an airplane,
an automobile, a ship, a railroad vehicle and the like.
[0003] One method of this type for manufacturing these composites
is an autoclave molding method where a plurality of prepreg
materials formed by impregnating reinforcement fiber sheet with
resin are stacked, covered by a bag film to be vacuumed, and then
pressurized and thermally cured by an autoclave. Another method is
a vacuum impregnation method where a mold release film and a mesh
sheet are arranged on reinforcement fiber sheets stacked on a mold
and they are covered by a bag film to be vacuumed while liquid
resin is injected inside the bag film to cure.
[0004] In these methods for manufacturing the composites, a major
part of the stacking operation of base material sheets made of
materials such as prepreg materials and reinforcement fiber sheets
is manually done. Thus it takes a lot of time and is not effective.
In view of improving the operation efficiency and the product
quality, a variety of apparatuses for stacking the base material
sheets have been proposed.
[0005] Disclosed in Patent Literatures 1 and 2 is an apparatus for
stacking roving materials formed by impregnating the reinforcement
fibers with resin. This apparatus winds the roving material drawn
from a supply unit around a stacking roller, and rolls the stacking
roller along the mold while pressing the roving material against
the mold so as to stack the roving material on the mold. Further,
disclosed in Patent Literature 3 is an apparatus for stacking
composite material tapes in a continuous manner, where a composite
material tape supplied from a material supply reel is pressed onto
a stacking member by a roller so as to stack the composite material
tapes in a continuous manner.
[0006] As a wind turbine blade for instance, there is a blade mold
70 having a shape of a saddle as shown in FIG. 9A. Herein, FIG. 9A
and FIG. 9B are illustrations of a conventional method for
manufacturing a fiber-reinforced base material. FIG. 9A is a
perspective view of the base material sheets stacked on the mold
using the base material roll. FIG. 9B is an enlarged
cross-sectional view of a section B of FIG. 9A. This blade mold 70
has a double-curved surface shape curving in X direction, i.e. a
width direction as well as in Y direction, i.e. a longitudinal
direction, a sheet supplying direction of the base material sheet
72. In this case, the base material roll 71 around which the base
material sheet 72 is winded rolls in the longitudinal direction of
the mold to extend the fiber 73. However, the mold 70 having a
double-curved surface shape changes in length depending on a
position in the width direction. Thus, by arranging the base
material sheet 72 along the mold 70, a wrinkle 80 occurs as shown
in FIG. 9B. Particularly, in the case where the fibers 73 are
unidirectional reinforcement fibers arranged along the
sheet-supplying direction, the unidirectional reinforcement fiber
has poor deformability on the mold 70 in in-plane direction unlike
cloth fabric and thus it is difficult to fit the unidirectional
reinforcement fiber along the curved surface of the mold 70.
[0007] Referring to FIG. 10A and FIG. 10B, generation of the
wrinkle 80 is described in details. When a flat base material sheet
72 is pressed onto the mold 70 having the saddle shape, the wrinkle
80 occurs in the base material sheet 72. Further, the base material
sheet 72 is a unidirectional reinforcement fiber whose fibers are
arranged unidirectionally along the longitudinal direction of the
mold 70.
[0008] As shown in FIG. 10A, the base material sheet 72 is arranged
such that its fiber direction coincides with the longitudinal
direction of the mold 70. The base material sheet 72 is pressed
onto the mold 70 from directly above so as to fit two sides A'D',
B'C' of the base material sheet 72 to arcs AD, BC of the mold 70 in
the width direction.
[0009] FIG. 10B shows a side view of the mold 70 and the base
material sheet 72 of FIG. 10A. As shown in a bottom drawing of FIG.
10B, a surface ABCD of the mold 70 (see FIG. 10A) is formed by the
arcs AB, DC such that the surface is concave from the arcs AB, DC
toward the arc EG. When the mold 70 is viewed from the side, the
arc EG is located lower than the arcs AB, DC. Further, the arc
length EG is shorter than the arc lengths AB, DC. The surface ABCD
of the mold 70 increases in arc length with distance from the arc
EG toward the arc AB or DC. In contrast, the surface A'B'C'D' of
the base material sheet 72 is flat and thus two sides A'B' and D'C'
have the same length as a distance between middle points E'G' in
the longitudinal direction. The middle points E', G' are located in
the middle between the two sides A'B' and D'C'.
[0010] Therefore, the length between the longitudinal middle points
E'G' of the base material sheet 72 is greater than that of the arc
EG of the mold 70. When the base material sheet 72 is stacked on
the mold 70 to fit the sides A'D' and B'C' of the base material
sheet 72 to the arcs AD and BC of the mold 70, the wrinkle 80
occurs near a part between widthwise middle points F'H'. The
widthwise middle points F', H' are located in the middle between
two sides A'B' and D'C' of the base material sheet 72 in the width
direction as shown in FIG. 10B. As described above, the surface
ABCD of the mold 70 increases in arc length with distance from the
arc EG toward the arc AB or DC. This contributes to generation of
the wrinkle 80. The number of wrinkles 80 occurring near the
widthwise middle points F'H' of the base material sheet, decreases
toward the side A'B' or the side D'C' of the base material sheet
72.
[0011] Patent Literature 4 discloses an apparatus for stacking the
base material sheet without causing wrinkles. The disclosed
apparatus is provided with a means for drawing the base material
sheet onto the mold and a means for pressing the base material
sheet onto the mold. The apparatus supplies the base material sheet
onto the mold while loading a tensile force on the base material by
the pressing means which is smaller in width than the base material
sheet. Upon receiving the tensile force, the base material sheet
deforms in the direction of the tensile force so that the base
material sheet can be stacked along the shape of the mold without
causing wrinkles.
CITATION LIST
Patent Literature
[PTL 1]
[0012] JP 6-39133 B
[PTL 2]
[0012] [0013] JP 4-62142 A
[PTL 3]
[0013] [0014] JP 5-254724 A
[PTL 4]
[0014] [0015] JP 2011-136432 A
SUMMARY
Technical Problem
[0016] As described above, when stacking the base material sheet
onto the mold having a double-curved surface shape according to
Patent Literatures 1 to 3, wrinkles are likely to occur. The
wrinkles cause a defect in the product, which leads to lower
production quality of the fiber-reinforced base material.
[0017] In contrast, the apparatus disclosed in Patent Literature 4,
deforms the base material sheet so as to generate a relative
displacement between a part of the base material sheet pressed by
the pressing means and a part of the base material sheet loaded
with the tensile force without being pressed. By this, it is
possible to remove a difference of the longitudinal length varying
in the width direction of the mold. However, if the mold is long,
the base material sheet is possibly subjected to large load from
repeated deformation in the direction of the tensile force. As a
result, this could affect the strength of the fiber-reinforced base
material.
[0018] In view of the present invention, it is an object of the
present invention to provide a method and an apparatus for
manufacturing a fiber-reinforced base material, which is capable of
manufacturing a fiber-reinforced base material of high quality
while preventing generation of defects such as wrinkles during
stacking of the base material sheet.
Solution to Problem
[0019] According to the present invention, a method for
manufacturing a fiber-reinforced base material formed by stacking a
base material sheet including a reinforcement fiber onto a mold
having a double-curved surface shape, comprises steps of:
[0020] supplying the base material sheet onto the mold from a base
material roll while applying distribution varying in a width
direction to a length of the base material sheet in a
sheet-supplying direction of the base material sheet in
correspondence with the double-curved surface shape of the mold;
and
[0021] applying pressure to the base material sheet in contact with
the mold.
[0022] The double-curved surface is a surface formed by collection
of curves. More specifically, the curved surface is formed such
that a line (a surface element) constituting a surface is a curved
surface element and a generating line and a director line are
constituted of curves. Herein, assuming that the surface is formed
by moving the curve, the moving line is the generating line and the
line which defines a movement of the generating line is the
director line. If at least one of the generating line or the
director line is a straight line, it is possible to press the
planar base material sheet against the mold without causing
wrinkles. However, the double-curved surface has the generating
line and the director line that are both curves. Thus, wrinkles
occur when pressing the planar base material sheet against the
mold.
[0023] Therefore, according to the above method for manufacturing
the fiber-reinforced base material, when supplying the base
material sheet onto the mold from the base material roll, the
distribution varying in the width direction is applied to the sheet
length in the sheet supplying direction in correspondence with the
double-curved surface shape of the mold. As a result, the base
material sheets can be stacked on the mold without causing defects
such as wrinkles even on the mold having the double-curved surface
shape. This makes it possible to manufacture the fiber-reinforced
base material of high quality.
[0024] The base material sheet refers to fabric in a sheet form
that is made of reinforcement fibers such as glass fibers and
carbon fibers. Further, the base material sheet may be a dry fabric
which is not impregnated with resin, or may be a prepreg material
whose fabric is impregnated with resin. The prepreg material is an
intermediate molding material formed by combining reinforcement
fiber and uncured resin in advance.
[0025] In the above method for manufacturing the fiber-reinforced
base material,
[0026] the base material roll has a circumferential length varying
in the width direction so as to apply the distribution to the
length of the base material sheet in the sheet-supplying direction,
and
[0027] while supplying the base material sheet onto the mold from
the base material roll, an outer periphery of the base material
roll is pressed against the mold over the base material sheet so as
to apply pressure to the base material sheet in contact with the
mold.
[0028] The base material roll has a circumferential length varying
in the width direction so as to apply the distribution to the
length of the base material sheet in the sheet-supplying direction.
Thus, even if the mold has the double-curved surface shape, the
base material sheet can be easily fit onto the mold without causing
wrinkles in the base material sheet. By rolling the base material
roll on the mold while pressing the base material roll against the
mold, the supplying and pressing of the base material sheet can be
performed at the same time, thereby reducing the operation
time.
[0029] Alternatively, in the above method for manufacturing the
fiber-reinforced base material,
[0030] the base material roll has a circumferential length varying
in the width direction so as to apply the distribution to the
length of the base material sheet in the sheet-supplying direction,
and
[0031] after supplying the base material sheet onto the mold from
the base material roll, the base material sheet is pressed against
the mold using an auxiliary roll so as to apply pressure to the
base material sheet in contact with the mold.
[0032] With the above configuration, even if the mold has the
double-curved surface shape, the base material sheet can be easily
fit onto the mold without causing wrinkles in the base material
sheet. Further, the base material sheet is pressed against the mold
by the auxiliary roll after the base material sheet is supplied on
the mold from the base material roll. Thus, even if the
double-curved surface shape of the mold does not completely match
the outer periphery of the base material roll, the auxiliary roll
firmly presses the base material sheet against the mold. This
enhances the freedom of the shape of the base material sheet.
[0033] As another alternative, in the above method for
manufacturing the fiber-reinforced base material,
[0034] a roll gap is formed between a convex roll and a concave
roll, the convex roll being a curved roll curving in the width
direction so that a diameter is greater in the center than at both
ends, the concave roll being arranged parallel to the convex roll
and being a curved roll curving in the width direction so that a
diameter is smaller in the center than at both ends,
[0035] the base material sheet drawn from the base material roll is
passed through the roll gap so as to apply the distribution to the
length of the base material sheet in the sheet-supplying direction,
and
[0036] after supplying the base material sheet having passed
through the roll gap onto the mold, the base material sheet is
pressed against the mold using an auxiliary roll so as to apply
pressure to the base material sheet in contact with the mold.
[0037] With the above configuration, the base material sheet drawn
from the base material roll is passed through the roll gap formed
between the convex roll and the concave roll to deform the base
material sheet and thus the distribution varying in the width
direction is applied to the length of the base material sheet in
the sheet-supplying direction. Therefore, even if the base material
roll is cylindrical or has a circumferential length varying in the
width direction, a small difference of the circumferential length
suffices to make the base material roll winded with the base
material sheet. Further, by using replaceable rolls for the roll
unit formed by the convex roll and the concave roll, the above
method can be used for a variety of molds. Furthermore, the base
material sheet is pressed against the mold by the auxiliary roll
after the base material sheet is supplied on the mold. Thus, even
if the double-curved surface shape of the mold does not completely
match the shape of the base material sheet deformed by the roll
unit, the auxiliary roll firmly presses the base material sheet
against the mold.
[0038] In this case, a sheet-bending angle formed around the roll
gap between the base material sheet after passing through the roll
gap and the base material sheet before passing through the roll gap
may be changed so as to adjust the distribution applied to the
length of the base material sheet in the sheet-supplying
direction.
[0039] By changing the sheet-bending angle formed around the roll
gap between the base material sheet after passing through the roll
gap and the base material sheet before passing through the roll
gap, the arc length of the base material sheet contacting the
convex roll or the concave roll is adjusted. In correspondence to
the change in the arc length, the distribution applied to the sheet
length in the sheet supplying direction changes as well. Therefore,
the distribution of the base material sheet is adjustable simply by
changing the sheet-bending angle of the base material sheet. The
sheet-bending angle is an angle formed between: a portion of the
base material sheet having passed through the roll gap and having
no contact with the convex roll and the concave roll; and a portion
of the base material sheet before passing through the roll gap and
having no contact with the convex roll and the concave roll. More
specifically, the portion having passed through the roll gap is a
portion of the base material sheet between the roll unit and the
auxiliary roll and the portion before passing through the roll gap
is a portion of the base material sheet between the base material
roll and the roll unit.
[0040] According to the present invention, an apparatus for
manufacturing a fiber-reinforced base material formed by stacking a
base material sheet including a reinforcement fiber onto a mold
having a double-curved surface shape, comprises:
[0041] a sheet supply unit for supplying the base material sheet
onto the mold from a base material roll while applying distribution
varying in a width direction to a length of the base material sheet
in a sheet-supplying direction of the base material sheet in
correspondence with the double-curved surface shape of the mold;
and
[0042] a sheet contact unit for applying pressure to the base
material sheet supplied onto the mold in contact with the mold.
[0043] As described above, the sheet supply unit supplies the base
material sheet onto the mold from the base material roll while
applying distribution varying in the width direction to the length
of the base material sheet in a the sheet-supplying direction of
the base material sheet in correspondence with the double-curved
surface shape of the mold. Thus, the base material sheet can be
stacked without causing defects such as wrinkles even on the mold
having the double-curved surface shape. This makes it possible to
manufacture the fiber-reinforced base material of high quality.
[0044] In the above apparatus for manufacturing the
fiber-reinforced base material,
[0045] the sheet supply unit comprises a base material roll whose
circumferential length varies in the width direction so as to apply
the distribution varying in the width direction to the length of
the base material sheet in the sheet supplying direction, the base
material roll being rolled along the mold to supply the base
material sheet onto the mold, and
[0046] the sheet contact unit presses the base material roll
against the mold when the base material roll is rolled so as to
apply pressure to the base material sheet in contact with the
mold.
[0047] As described above, the sheet supply unit comprises the base
material roll whose circumferential length varies in the width
direction and the base material roll is rolled along the mold to
supply the base material sheet onto the mold. Thus, even if the
mold has the double-curved surface shape, the base material sheet
can be easily fit onto the mold without causing wrinkles in the
base material sheet. Further, the sheet contact unit presses the
base material roll against the mold when rolling the base material
roll. Thus supplying and pressing of the base material sheet can be
performed at the same time.
[0048] As one alternative in the above apparatus for manufacturing
the fiber-reinforced base material,
[0049] the sheet supply unit comprises a base material roll whose
circumferential length varies in the width direction so as to apply
the distribution varying in the width direction to the length of
the base material sheet in the sheet supplying direction, the base
material roll being rolled along the mold to supply the base
material sheet onto the mold, and
[0050] the sheet contact unit comprises an auxiliary roll for
pressing the base material sheet arranged on the mold against the
mold so as to apply pressure to the base material sheet in contact
with the mold.
[0051] The manufacturing apparatus is provided with the sheet
supply unit. In a manner similar to the above, even if the mold has
the double-curved surface shape, the base material sheet can be
easily fit onto the mold without causing wrinkles in the base
material sheet. Further, the sheet supply unit comprises the
auxiliary roll for pressing the base material sheet arranged on the
mold against the mold. Thus, even if the double-curved surface
shape of the mold does not completely match the outer periphery of
the base material roll, the auxiliary roll can firmly press the
base material sheet against the mold. This enhances the freedom of
the shape of the base material sheet.
[0052] As another alternative in the above apparatus for
manufacturing the fiber-reinforced base material,
[0053] the sheet supply unit comprises a convex roll and a concave
roll, the convex roll curving in the width direction so that a
diameter is greater in the center than at both ends, the concave
roll being arranged parallel to the convex roll and curving in the
width direction so that a diameter is smaller in the center than at
both ends, the convex roll and the convex roll forming a roll gap
therebetween where the base material sheet drawn from the base
material roll is passed through so as to apply the distribution to
the length of the base material sheet in the sheet-supplying
direction, and
[0054] the sheet contact unit comprises an auxiliary roll for
pressing base material sheet against the mold so as to apply
pressure to the base material sheet in contact with the mold.
[0055] As described above, the sheet supply unit comprises the
convex roll and the concave roll and the base material sheet is
passed through the roll gap, thereby deforming the base material
sheet. In this manner, the distribution varying in the width
direction is applied to the length of the base material sheet in
the sheet-supplying direction. Therefore, even if the base material
roll is cylindrical or has a circumferential length varying in the
width direction, a small difference of the circumferential length
suffices to make the base material roll winded with the base
material sheet. Further, by using replaceable rolls for the roll
unit formed by the convex roll and the concave roll, the above
apparatus is applicable to a variety of molds. Furthermore, the
base material sheet is pressed against the mold by the auxiliary
roll after the base material sheet is supplied on the mold. Thus,
even if the double-curved surface shape of the mold does not
completely match the shape of the base material sheet deformed by
the roll unit, the auxiliary roll firmly presses the base material
sheet against the mold.
[0056] In this case, the above apparatus for manufacturing the
fiber-reinforced base material may further comprise an angle
adjustor for adjusting a sheet-bending angle around the roll gap
between the base material sheet after passing through the roll gap
and the base material sheet before passing through the roll
gap.
[0057] By means of the angle adjustor for adjusting the
sheet-bending angle, the distribution of the base material sheet is
adjustable simply by changing the sheet-bending angle of the base
material sheet. The angle adjustor may be, for instance, a means
for adjusting relative positions of at least two of the base
material roll, the roll unit or the auxiliary roll. By adjusting
the relative positions, the sheet-bending angle can be
adjusted.
Advantageous Effects
[0058] According to the present invention, when supplying the base
material sheet onto the mold from the base material roll, the
distribution varying in the width direction is applied to the
length of the sheet in the sheet supplying direction in
correspondence with the double-curved surface shape of the mold. As
a result, the base material sheet can be stacked on the mold
without causing defects such as wrinkles even on the mold having
the double-curved surface shape. This makes it possible to
manufacture the fiber-reinforced base material of high quality.
BRIEF DESCRIPTION OF DRAWINGS
[0059] FIG. 1 is a perspective view of an apparatus for
manufacturing a fiber-reinforced base material according to a first
embodiment of the present invention.
[0060] FIG. 2 is a perspective view of an apparatus for
manufacturing a fiber-reinforced base material according to a
second embodiment of the present invention.
[0061] FIG. 3 is an illustration of a detailed example of the
apparatus shown in FIG. 2.
[0062] FIG. 4 is a perspective view of an apparatus for
manufacturing a fiber-reinforced base material according to a third
embodiment of the present invention.
[0063] FIG. 5 is a side view of the apparatus shown in FIG. 4.
[0064] FIG. 6A is a side view of each roll as an explanatory
drawing of a configuration example of the third embodiment.
[0065] FIG. 6B is a perspective view of a mold in correspondence
with the roll.
[0066] FIG. 7A is a side view of each roll as an explanatory
drawing of another configuration example of the third
embodiment.
[0067] FIG. 7B is a perspective view of a mold in correspondence
with the roll.
[0068] FIG. 8A is a perspective view of a mold used in embodiments
of the present invention.
[0069] FIG. 8B is an enlarged view of a section A of FIG. 8A.
[0070] FIG. 9A is a perspective illustration of a base material
sheet being stacked on the mold using a base material roll
according to a conventional method for manufacturing the
fiber-reinforced base material.
[0071] FIG. 9B is an enlarged-cross-sectional view of a section B
of FIG. 9A.]
[0072] FIG. 10A is an explanatory view of generation of wrinkles in
the base material sheet.
[0073] FIG. 10B is a flat view of FIG. 10A.
DETAILED DESCRIPTION
[0074] Embodiments of the present invention will now be described
in detail with reference to the accompanying drawings. It is
intended, however, that unless particularly specified in these
embodiments, dimensions, materials, shape, its relative positions
and the like shall be interpreted as illustrative only and not
limitative of the scope of the present invention.
First Embodiment
[0075] In reference to FIG. 1, an apparatus for manufacturing a
fiber-reinforced base material according to a first embodiment of
the present invention is explained. The manufacturing apparatus 1
according to the present embodiment makes a stacked product by
stacking a base material sheet including a reinforcement fiber 6 on
a mold 2 having a double-curved surface shape. The stacked product
is used, for instance, as a preform when making a fiber reinforced
plastic composite using an autoclave molding method, vacuum
impregnation method or the like. The base material sheet 5 herein
refers to fabric in a sheet form that is formed of reinforcement
fiber 6 such as glass fiber and carbon fiber. Further, the base
material sheet 5 may be dry fabric which is not impregnated with
resin, or may be a prepreg material whose fabric is impregnated
with resin. The present embodiment is particularly applicable when
the reinforcement fiber 6 is unidirectional reinforcement fiber
arranged in a longitudinal direction of the mold 2 (a
sheet-supplying direction).
[0076] The manufacturing apparatus 1 for the fiber-reinforced base
material according to the present embodiment is mainly provided
with a base material roll 10 serving a dual function as a sheet
supply unit and a sheet pressing unit, and a transferring mechanism
20 for transferring the base material roll 10 in the longitudinal
direction of the mold 2.
[0077] The base material roll 10 has a circumferential length
varying in the width direction so as to apply a distribution
varying in the width direction to the length of the base material
sheet 5 in the sheet-supplying direction. Herein, the
sheet-supplying direction is a direction indicated by Y in the
drawing and the width direction is a direction indicated by X in
the drawing. The drawing shows the base material roll 10 having a
concave drum shape as an example. The base material roll 10 is a
concave roll (concave in cross-section) curving in the width
direction so that a diameter is smaller in the center 12 than at
both ends 11. The difference of the circumferential length in the
width direction corresponds to the double-curved surface shape of
the mold 2. The drawing also shows the mold 2 of a saddle shape.
Configuration examples of the mold 2 are described later in
details. Further, the shape of the outer periphery of the base
material roll may be curved in correspondence with the shape of the
mold 2.
[0078] The base material sheet 5 is winded around the outer
periphery of the base material roll 10. More specifically, the base
material sheet 5 is winded around the outer periphery of the base
material roll 10 having the circumferential length varying in the
width direction and thus the length of the base material sheet 5 in
the longitudinal direction varies in the width direction.
[0079] The base material roll 10 is rotatably connected to a
transferring mechanism 20. The base material roll 10 is rollable
along the mold 2 to supply the base material sheet 5 onto the mold
2. Further, the base material roll 10 presses the base material
sheet 5 against the mold 2 while rotating and moving, so as to
apply pressure to the base material sheet in contact with the mold
2. In this process, the pressure may be applied to the base
material sheet 5 in contact with the mold 2 using the weight of the
base material roll 10 or by pressing the base material roll 10
against a surface of the base material sheet 5 using an actuator
(not shown) connected rotatably to a shaft 13 of the base material
roll 10.
[0080] The transferring mechanism 20 includes a pair of
transferring rails 21 arranged on both sides of the mold 2 along
the longitudinal direction, a pair of transferring rollers 22
rotating on the pair of transferring rails 21, and support rods 23
supporting the shaft 13 of the base material roll 10 rotatably to
the transferring rollers 22. A power means (not shown) applies a
force to the shaft 14 of the base material roll 10 in a direction
indicated by an arrow in FIG. 1. As a result, the transferring
rollers 22 rotate on the transferring rails 21 to move the base
material roll 10 along the transferring rails 21. Herein, the power
means may be configured, for instance, such that the shaft 13 is
manually moved via a handle (not shown) connected rotatably to the
shaft 13, or such that the shaft 13 is automatically moved by a
driving mechanism connected rotatably to the shaft 13. The
transferring mechanism may be configured to move the shaft 13 by
rotating and moving the transferring rollers 22 by the driving
mechanism connected to the transferring rollers 22.
[0081] In reference to FIG. 1, a method for manufacturing the
fiber-reinforced base material according to the present embodiment
is described. Herein, the base material sheet 5 is stacked on the
mold 2 of the wind turbine blade as an example.
[0082] As shown in FIG. 1, the manufacturing apparatus 1 for
manufacturing the fiber-reinforced base material moves the base
material roll 10 on the mold 2 along the transferring rails 21 by
moving the shaft 13 of the base material roll 10 in the
longitudinal direction of the mold 2 using the power means (not
shown). In response to the movement, the base material roll 10
rolls over the mold 2 to supply the base material sheet 5 onto the
mold 2 from the base material roll 10 and at the same time presses
the base material sheet 5 against the mold 2. Meanwhile, as the
base material roll 10 has the circumferential length varying in the
width direction (X direction) in correspondence to the
double-curved surface shape of the mold 2 so as to apply
distribution varying in the width direction to the sheet length in
the sheet supplying direction (Y direction) when supplying the base
material sheet 5 onto the mold 2. Then, once supplying and pressing
the base material sheet 5 over the entire length of the mold 2, the
base material roll 10 is returned so as to move the base material
roll 10 over the mold 2 again. In this manner, supplying and
pressing of the base material sheet 5 over the entire length of the
mold 2 are repeated to stack the base material sheets 5 on the mold
2.
[0083] As described above, in the present embodiment, when
supplying the base material sheet 5 onto the mold 2 from the base
material roll 10, the distribution varying in the width direction
is applied to the length of the base material sheet 5 in the sheet
supplying direction in correspondence to the double-curved surface
shape of the mold 2. Thus the base material sheet 5 can be stacked
without causing defects such as wrinkles even on the mold having
the double-curved surface shape. This makes it possible to
manufacture the fiber-reinforced base material of high quality.
[0084] By varying the circumferential length of the base material
roll 5 in the width direction, the distribution can be applied to
the sheet length in the sheet-supplying direction. Thus, even if
the mold has the double-curved surface shape, the base material
sheet 5 can be easily deformed to fit onto the mold 2 without
causing wrinkles in the base material sheet 5. By rolling the base
material roll 5 on the mold 2 while pressing the base material roll
5 against the mold 2, the supplying and pressing of the base
material sheet 5 can be performed at the same time, thereby
reducing the operation time.
Second Embodiment
[0085] In reference to FIG. 2 and FIG. 3, the apparatus for
manufacturing the fiber-reinforced base material is described. FIG.
2 is a perspective view of the apparatus for manufacturing the
fiber-reinforced base material according to a second embodiment of
the present invention. FIG. 3 is an illustration of a detailed
example of the apparatus shown in FIG. 2. The same reference
numerals are given without adding explanations for those parts that
are the same as the first embodiment and parts different from the
first embodiment are mainly explained here.
[0086] The apparatus for manufacturing the fiber-reinforced base
material according to the present embodiment is mainly provided
with a base material roll 30 as the sheet supply unit, an auxiliary
roll 35 as the sheet pressing unit, the transferring mechanism 20
for transferring the base material roll 30 in the longitudinal
direction of the mold 2 and a driving mechanism for driving the
auxiliary roll 35 in the longitudinal direction of the mold 2.
[0087] The base material roll 30 has a circumferential length
varying in the width direction so as to apply a distribution
varying in the width direction to the length of the base material
sheet 5 in the sheet-supplying direction. The difference of the
circumferential length in the width direction may correspond to the
double-curved surface shape of the mold 2. However, this is not
limitative and the difference of the circumferential length may be
smaller than the double-curved surface shape. The drawings show the
base material roll 30 having a concave drum shape as an example.
The base material roll 30 is a concave roll (concave in
cross-section) curving in the width direction so that a diameter is
smaller in the center 32 than at both ends 31. The base material
sheet 5 is winded around the outer periphery of the base material
roll 30 and the length of the base material sheet 5 varies in the
width direction. The base material roll 30 is rotatably connected
to the transferring mechanism 20. The base material roll 30 is
rollable along the mold 2.
[0088] The auxiliary roll 35 has a circumferential length varying
in the width direction to correspond to the double-curved surface
shape of the mold 2. The drawings show the auxiliary roll 35 having
a concave drum shape as an example. The auxiliary roll 35 is a
concave roll (concave in cross-section) curving in the width
direction so that a diameter is smaller in the center 37 than at
both ends 36.
[0089] The auxiliary roll 35 is arranged downstream from the base
material roll 30 in the transferring direction with a certain
distance from the base material roll 30. Further, a shaft 38 of the
auxiliary roll 35 is connected rotatably to a driving mechanism 25.
The auxiliary roll 35 is rolled on the mold in the longitudinal
direction by the driving mechanism 25. The distance between the
auxiliary roll 35 and the base material roll 30 may be fixed or
variable. The auxiliary roll 35 and the base material roll 30 may
move in conjunction or move independently. FIG. 3 shows an example
where the auxiliary roll 35 and the base material roll 30 are
connected by a connection frame 39 so that the auxiliary roll 35
and the base material roll 30 move in conjunction with each
other.
[0090] The auxiliary roll 35 rolls on the base material sheet 5
supplied by the base material roll 30 and presses the base material
sheet 5 against the mold 2 so as to apply pressure to the base
material sheet 5 in contact with the mold 2. In this process, the
pressure may be applied to the base material sheet 5 in contact
with the mold 2 using the weight of the auxiliary roll 35 or by
pressing the auxiliary roll 35 against a surface of the base
material sheet 5 by means of an arm 28 attached to the driving unit
25 so as to apply pressure to the base material sheet 5 in contact
with the mold 2. The auxiliary roll 35 may be made of deformable
material such as silicon rubber and is applicable to be used for a
mold having a curve shape varying in the width direction.
[0091] The driving mechanism 25 includes a base housing a motor,
traveling rollers 27 attached to a bottom of the base 26, an arm 28
attached to the base at one end and attached to the auxiliary roll
35 at the other end, and traveling rails 28 arranged beside the
mold 2 along the mold 2.
[0092] The traveling rollers 27 are rotated by the motor housed in
the base 26 and roll on the traveling rails 29. The arm 28 is
formed by an arm part 28a extending horizontally, and an actuator
28b arranged between the arm part 28a and the auxiliary roll 35. As
the actuator 28b, a hydraulic cylinder, a motor cylinder and the
like can be used, for example. The actuator 28b is extendible in a
vertical direction and its extendible side is attached to the shaft
38 of the auxiliary roll 35. As a result, by driving the actuator
28b, the shaft 38 of the auxiliary roll 35 is pressed downward in
the vertical direction, i.e. toward the base material sheet 5.
[0093] In reference to FIG. 2 and FIG. 3, the method for
manufacturing the fiber-reinforced base material according to the
present embodiment is described.
[0094] As shown in FIG. 3, the manufacturing apparatus 1 for
manufacturing the fiber-reinforced base material moves, in the
longitudinal direction of the mold 2, the base material roll 30
connected to the auxiliary roll 35 via a support frame 39 by moving
the shaft 38 of the auxiliary roll 35 in the longitudinal direction
of the mold 2 using the driving mechanism 25. In this process, by
means of the transferring mechanism 20 connected to the shaft 33 of
the base material roll 30, the base material roll 30 moves on the
transferring rails 21 along the mold 2.
[0095] In response to the movement, the base material roll 30 rolls
on the mold 2 to supply the base material sheet 5 onto the mold 2
from the base material roll 30. Meanwhile, as the base material
roll 30 has the circumferential length varying in the width
direction in correspondence to the double-curved surface shape of
the mold 2 so as to apply distribution varying in the width
direction to the sheet length in the sheet supplying direction when
supplying the base material sheet 5 onto the mold 2.
[0096] The auxiliary roll 35 moving behind the base material roll
30 rolls on the base material sheet 5 supplied from the base
material roll 30. The outer periphery of the auxiliary roll 35 is
shaped to correspond to the double-curved surface shape of the mold
2. Thus, with rolling of the auxiliary roll 35 on the base material
sheet 5, the base material sheet 5 is applied with pressure in
contact with the mold 2. The base material sheet 5 may be pressed
onto the mold 2 by pressing the auxiliary roll 35 downward in the
vertical direction by the actuator 28b.
[0097] Once supplying and pressing the base material sheet 5 over
the entire length of the mold 2 by the base material roll 30 and
the auxiliary roll 35, the base material roll 30 and the auxiliary
roll 35 are moved on the mold 2 again. In this manner, supplying
and pressing of the base material sheet 5 over the entire length of
the mold 2 are repeated to stack the base material sheets 5 on the
mold 2.
[0098] As described above, according to the present embodiment, the
base material sheet 5 can be stacked without causing defects such
as wrinkles even on the mold having the double-curved surface
shape. This makes it possible to manufacture the fiber-reinforced
base material of high quality.
[0099] Further, the base material sheet 5 is pressed against the
mold 2 by the auxiliary roll 35 after the base material sheet 5 is
supplied on the mold 2 from the base material roll 30. Thus, even
if the double-curved surface shape of the mold 2 does not
completely match the outer periphery of the base material roll 30,
the auxiliary roll 35 positively presses the base material sheet 5
against the mold 2. This enhances the freedom of the shape of the
base material sheet 5.
Third Embodiment
[0100] Described in reference to FIG. 4 and FIG. 5 is the apparatus
1 for manufacturing the fiber-reinforced base material according to
a third embodiment. FIG. 4 is a perspective view of the apparatus
for manufacturing the fiber-reinforced base material according to
the third embodiment of the present invention. FIG. 5 is an
illustration of a detailed example of the apparatus shown in FIG.
4. The same reference numerals are given without adding
explanations for those parts that are the same as the first and
second embodiments and parts different from the first and second
embodiments are mainly explained here.
[0101] The apparatus 1 for manufacturing the fiber-reinforced base
material according to the present embodiment is mainly provided
with a base material roll 40 as the sheet supply unit, a convex
roll 42 and a concave roll 43, an auxiliary roll 45 as the sheet
pressing unit, and a frame 50 supporting the sheet supply unit and
the sheet pressing unit, and the transferring mechanism (not shown)
for transferring the frame 50 in the longitudinal direction of the
mold 2.
[0102] Around the base material roll 40, the base material sheet 5
is winded. The base material roll 40 is supported rotatably by the
frame 50. The base material roll 40 is formed into a cylindrical
shape. Thus the base material sheet 5 winded around the base
material roll 40 has a planar shape. Further, the base material
roll 40 may be curved a circumferential length slightly varying in
correspondence to the double-curved surface shape of the mold
2.
[0103] The convex roll 42 may be curved in the width direction
(convex in cross-section) so that a diameter is greater in the
center than at both ends. The concave roll 43 may be curved in the
width direction (concave in cross-section) so that a diameter is
smaller in the center than at both ends. The convex roll 42 and the
concave roll 43 are arranged adjacent to each other so that their
shafts are parallel. Between the outer periphery of the convex roll
42 and the outer periphery of the concave roll 43, a roll gap 44 is
formed. The distance of the roll gap 44 is approximately the small
as or slightly smaller than the thickness of the base material
sheet 40. The convex roll 42 and the concave roll 43 are
collectively called as a roll unit 41. The roll unit 41 is
configured so that the roll gap is shaped corresponding to the
double-curved surface shape of the mold 2. The roll unit 41 may be
configured so that the convex roll 42 is approximately as wide as
the concave roll 43 and ends of the convex roll 42 are arranged to
coincide with ends of the concave roll 43. In this case, the center
position of the roll unit 41 in the width direction coincide
substantially with the center position of the base material sheet 5
n the width direction as well as the center position of the mold 2
in the width direction. Further, both ends of the roll unit 41 in
the width direction coincide with both ends of the base material
sheet 5 in the width direction as well as both ends of the mold 2
in the width direction.
[0104] In the sheet supply unit having the above structure, the
base material sheet 5 drawn from the base material roll 40 passes
through the roll gap 44 between the convex roll 42 and the concave
roll 43 so that the distribution varying in the width direction is
applied to the sheet length in the sheet supplying direction in
correspondence to the double-curved surface shape of the mold 2. In
such a state that the base material sheet 5 is applied with the
distribution, the base material sheet 5 is supplied onto the mold
5. In the present embodiment, the base material sheet 5 may be a
prepreg material formed by impregnating a reinforcement fiber sheet
with resin to make it easier to maintain the shape formed by going
through the roll gap 44.
[0105] The auxiliary roll 45 has a circumferential length varying
in the width direction to correspond to the double-curved surface
shape of the mold 2. The drawings show the auxiliary roll 45 having
a concave drum shape as an example. The auxiliary roll 45 is a
concave roll (concave in cross-section) curving in the width
direction so that a diameter is smaller in the center 47 than at
both ends 46.
[0106] The auxiliary roll 45 is arranged downstream from the sheet
supply unit in the transferring direction with a certain distance
from the roll unit 41. The auxiliary roll 45 presses the base
material sheet 5 drawn out by the sheet supply unit against the
mold 2 so as to apply pressure to the base material sheet 5 in
contact with the mold 2. In a manner similar to the second
embodiment, the auxiliary roll 45 may be connected to the driving
mechanism 25 or may be configured to be applied with a pressing
force by the actuator against the mold 2 (see FIG. 4).
[0107] Further, the convex roll 42 and the concave roll 43 may each
have the circumferential length varying the width direction (a
diameter in the width direction) more than the auxiliary roll 45.
As a result, even after exiting the auxiliary roll 45, the base
material sheet 5 maintains difference of the circumferential length
(the difference of the longitudinal length in the width direction)
in correspondence to the difference of the circumferential length
of the mold 2 (the difference of the longitudinal length in the
width direction).
[0108] The base material roll 40, the roll unit 41 and the
auxiliary roll 45 may each be supported rotatably by a frame (not
shown). In this case, the frame is movable in the longitudinal
direction along the mold by the driving unit.
[0109] The manufacturing apparatus of the present embodiment may
also include an angle adjustor for adjusting a sheet-bending angle
around the roll gap 44 between a portion 5a of the base material
sheet portion having passed through the roll gap 44 and a portion
5b of the base material sheet before passing through the roll gap
44. The angle adjustor, for instance, is a means for adjusting
relative positions of at least two of the base material roll 40,
the roll unit 41 or the auxiliary roll 45. By adjusting the
relative positions, the sheet-bending angle becomes adjustable.
[0110] The sheet-bending angle is an angle formed between: the
portion 5a of the base material sheet 5 having passed through the
roll gap 44 and having no contact with the convex roll 42 and the
concave roll 42; and the portion 5b of the base material sheet 5
before passing through the roll gap 44 and having no contact with
the convex roll 42 and the concave roll 42. More specifically, the
portion 5a is a portion of the base material sheet 5 between the
roll unit 41 and the auxiliary roll 45 and the portion 5b is a
portion of the base material sheet 5 between the base material roll
40 and the roll unit 41. In the above case, the arc length of the
base material sheet 5 contacting the convex roll 42 or the concave
roll 42 is adjusted by changing the sheet-bending angle .alpha.,
.beta. formed between the portion 5a of the base material sheet 5
having passed through the roll gap 44 and the portion 5b before
passing through the roll gap 44. In correspondence to the change in
the arc length, the distribution applied to the sheet length in the
sheet supplying direction changes as well. Therefore, the
distribution of the base material sheet is adjustable simply by
changing the sheet-bending angle of the base material sheet 5.
[0111] In reference to FIG. 4 and FIG. 5, the method for
manufacturing the fiber-reinforced base material according to the
present embodiment is described.
[0112] The manufacturing apparatus 1 for manufacturing the
fiber-reinforced base material moves in the longitudinal direction
the base material roll 40, the roll unit 41 and the auxiliary roll
45 simultaneously by means of the driving mechanism. In response to
the movement, the base material sheet 5 is drawn out from the base
material roll 4. The base material sheet 5 may be drawn out from
the base material roll 40 by winding the base material sheet 5
around the auxiliary roll 45, or may be drawn out by means of a
separate unit for drawing out the base material sheet 5.
[0113] The base material sheet 5 drawn out from the base material
roll 40 passes through the roll gasp 44 of the roll unit 41 and
then is supplied onto the mold 2. In this process, the roll gap is
shaped corresponding to the double-curved surface shape of the mold
2. Thus, the base material sheet 5 passes through the roll gap 44
between the convex roll 42 and the concave roll 43 so that the
distribution varying in the width direction is applied to the sheet
length in the sheet supplying direction in correspondence to the
double-curved surface shape of the mold 2. In such a state that the
base material sheet 5 is applied with the distribution, the base
material sheet 5 is supplied onto the mold 5.
[0114] Meanwhile, the sheet-bending angle formed between the
portion 5a having passed through the roll gap 44 and the portion 5b
before passing through the roll gap 44 may be adjusted by the angle
adjustor. The sheet-bending angle may be adjusted in correspondence
to the double-curved surface shape of the mold 3. The sheet-bending
angle can be adjusted by changing the relative positions of at
least two of the base material roll 40, the roll unit 41 or the
auxiliary roll 45.
[0115] In reference to FIG. 6A, FIG. 6B, FIG. 7A and FIG. 7B, a
configuration example according to the third embodiment is
described in details. FIG. 6A is a side view of each roll as an
explanatory drawing of a configuration example of the third
embodiment. FIG. 6B is a perspective view of a mold in
correspondence with the roll.
[0116] The configuration of each roll shown in FIG. 6A is
substantially the same as that in FIG. 4 and FIG. 5. As shown in
FIG. 6A, the sheet-bending angle .alpha. is formed between the
direction A of the base material sheet 5 having passed through the
roll gap 44 and the direction B of the base material sheet before
passing through the roll gap 44. The directions A and B are taken
at an edge of the base material sheet 5. However, this is not
limitative and the directions A and B may be taken in the center of
the base material sheet 5 or in any cross section in the width
direction of the base material sheet 5. The distribution of the
sheet length in the width direction of the base material sheet is
adjustable by adjusting the sheet-bending angle .alpha.. More
specifically, the greater the sheet-bending angle .alpha. is, the
longer the arc length of the base material sheet 5 contacting the
concave roll 43 is. The concave roll 43 has the circumferential
length varying in the width direction. Thus, the longer the arc
length contacting the concave roll 43 is, the greater the
difference of the sheet length in the sheet-supplying direction
becomes in the width direction of the base material sheet 5. By
changing the sheet-bending angle .alpha., the distribution of the
sheet length in the sheet-supplying direction can be adjusted in
the width direction of the base material sheet.
[0117] The base material sheet 5 supplied onto the mold 2 is
pressed by the auxiliary roll 45 rolling on the base material sheet
5 so as to apply pressure to the base material sheet 5 in contact
with the mold 2.
[0118] Once supplying and pressing the base material sheet 5 over
the entire length of the mold 2 by the base material roll 40, the
roll unit 41 and the auxiliary roll 45, the frame is turned so as
to move the base material roll 40, the roll unit 41 and the
auxiliary roll 45 on the mold 2 again. In this manner, supplying
and pressing of the base material sheet 5 over the entire length of
the mold 2 are repeated to stack the base material sheets 5 on the
mold 2.
[0119] The manufacturing apparatus having the configuration of FIG.
6A is used in the case where the mold 2 has a saddle shape as shown
in FIG. 6B. The mold 2 having the saddle shape has a concave shape
in the X direction (the width direction) curving downward toward a
center and has a convex shape in the Y direction (the longitudinal
direction) curving upward toward the center.
[0120] In contrast, the manufacturing apparatus having the
configuration of FIG. 7A is used in the case where the mold 2 has a
plate-like shape as shown in FIG. 7B. The mold 2 having the
plate-like shape has a convex shape in the X direction (the width
direction) curving upward toward a center and has a convex shape in
the Y direction (the longitudinal direction) curving upward toward
the center.
[0121] The roll unit 41 of this manufacturing apparatus is provided
with the convex roll 43 on the upper side and the concave roll 42
on the lower side. Further, the auxiliary roll 45 is a concave roll
whose diameter 6 is smaller at the center 4 than at both ends 47 in
the width direction. The base material roll 40 is arranged
downstream from the roller unit 41 in the supply direction of the
base material sheet 5. Thus, the sheet-bending angle .beta. formed
between the direction A of the base material sheet 5 having passed
through the roll gap 44 and the direction B of the base material
sheet 5 before passing through the roll gap 44 is greater than
180.degree.. With the above arrangement of each roll and the
sheet-bending angle .beta., the present embodiment is applicable to
the mold 2 having the plate-like shape.
[0122] In reference FIG. 8A an FIG. 8B, a blade mold is explained
as a configuration example of the mold used in the present
embodiment. FIG. 8A is a perspective view of the mold used in
embodiments of the present invention. FIG. 8B is an enlarged view
of a section A of FIG. 8A.
[0123] As shown in FIG. 8A and FIG. 8B, the blade mold 2 used in
the present embodiment is shaped along a shape of a wind turbine
blade. The mold 2 for the wind turbine blade can be divided into a
pressure side facing the wind and a suction side on the opposite
side at a leading edge and a trailing edge as a parting line. The
mold 2 of FIG. 8A is the suction side of the blade mold.
[0124] The suction-side mold 2 shown in FIG. 8A is placed in such a
state that the where the base material sheets 5 (see FIG. 1) are
stacked faces upward. The mold 2 extends in the longitudinal
direction and curves in a concave shape (a convex downward) in the
width direction of the mold 2 (in a direction of a blade chord in a
blade section). Further, as shown in FIG. 8B showing an enlarged
view of the section A of FIG. 8A, a part of the surface of the mold
2 where the base material sheets 5 are stacked is upward convex in
the longitudinal direction of the mold 2 and is concave in the
width direction in a shape of a saddle (non-Euclidean). More
specifically, the surface of the mold 2 where the base material
sheets 5 are stacked is configured such that the longitudinal arcs
AB, EG, DC are upward convex and the width-wise arcs AD, EG, BC are
concave. Thus the surface ABCD formed by connecting ends A, B, C, D
of the arcs has a concave shape overall. The diameter Rc of the arc
EG is smaller than the diameter Re of the arcs AB, DC. Further, the
mold 2 shown in FIG. 8A and FIG. 8B is just an example and the
present embodiment is applicable to molds of any type having a
double-curved surface.
[0125] As described above, according to the present embodiments,
the base material sheet 5 can be stacked without causing defects
such as wrinkles even on the mold having the double-curved surface
shape. This makes it possible to manufacture the fiber-reinforced
base material of high quality.
[0126] Further, the base material sheet 5 is passed through the
roll gap 44 between the convex roll 42 and the concave roll 43 so
as to deform the shape. Thus, the distribution varying in the width
direction is applied to the sheet length in the sheet supplying
direction. Therefore, even if the base material roll 5 is
cylindrical or has a circumferential length varying in the width
direction, a small difference of the circumferential length
suffices to produce the base material roll 40 winded with the base
material sheet 5. Furthermore, by using replaceable rolls for the
roll unit 41 formed by the convex roll 42 and the concave roll 43,
the above method and apparatus can be used for a variety of molds.
Moreover, the base material sheet 5 is pressed against the mold 2
by the auxiliary roll 45 after the base material sheet 5 is
supplied on the mold 2. Thus, even if the double-curved surface
shape of the mold 2 does not completely match the shape of the base
material sheet deformed by the roll unit 41, the auxiliary roll 45
positively presses the base material sheet 5 against the mold
2.
[0127] While the embodiments of the present invention have been
described, it is obvious to those skilled in the art that the first
to third embodiments may be combined as needed and that various
changes may be made without departing from the scope of the
invention.
[0128] Further, the embodiments are applicable to molds of types
other than the wind turbine blade. For instance, the embodiments
are applicable to molds of structures having the double-curved
surface to be used in a wind mill, an airplane, an automobile, a
ship, a railroad vehicle and the like.
REFERENCE SIGNS LIST
[0129] 1 APPARATUS FOR MANUFACTURING FIBER-REINFORCED BASE MATERIAL
[0130] 5 MOLD [0131] 6 BASE MATERIAL SHEET [0132] 10, 30, 40 BASE
MATERIAL ROLL [0133] 20 TRANSFERRING UNIT [0134] 21 TRANSFERRING
RAIL [0135] 22 TRANSFERRING ROLLER [0136] 23 SUPPORT ROD [0137] 25
MOTOR [0138] 26 ARM [0139] 27 TRAVELING ROLLER [0140] 28 ARM [0141]
28a ARM PART [0142] 28b ACTUATOR [0143] 29 TRAVELING RAIL [0144]
35, 45 AUXILIARY ROLL [0145] 41 ROLL UNIT [0146] 42 CONVEX ROLL
[0147] 43 CONCAVE ROLL [0148] 44 ROLL GAP
* * * * *